Preparation of aromatic isocyanates by catalytic carbonylation of corresponding nitro compound

ABSTRACT

THE PROCESS FOR PREPARING AN ORGANIC ISOCYANATE BY REACTING AN ORGANIC NITRO COMPOUND WITH CARBON NOMOXIDE IN THE PRESENCE OF A CATALYST SYSTEM COMPRISING A HALIDE OF NOBLE METAL AND A NITROSO COMPOUND. PREFERRED NITROSO COMPOUNDS INCLUDE 1-NITROSO-2-NAPHTHOL, 2-NITROSO-1-NAPHTHOL, NITROSEBENZENE, AND ISONITROSO ACETROPHENONE. THE NOBLE METAL HALIDE IS PREFERABLY A HALIDE OF PALLADIUM, RHODIUM, IRDIUM, REHENIUM, PLATINUM, AND MIXTURES THEREOF. THE CATALYST SYSTEM MAY ALSO INCLUDE MOLYBDENUM TRIOXIDE OR ANOTHER METAL OXIDE.

United States Patent Offl ce 3,637,786 PREPARATION OF AROMATIC ISOCYANATES BY CATALYTIC CARBONYLATION F CORRE- SPONDING NlTRO COMPOUND Eric Smith, Madison, Conn., assignor to Olin Mathieson Chemical Corporation No Drawing. Filed Feb. 10, 1969, Ser. No. 798,177 Int. Cl. C07c 119/04 US. Cl. 260-453 P 19 Claims ABSTRACT OF THE DISCLOSURE The process for preparing an organic isocyanate by reacting an organic nitro compound with carbon monoxide in the presence of a catalyst system comprising a halide of a noble metal and a nitroso compound.

Preferred nitroso compounds include l-nitroso-Z-naphthol, Z-nitroso-l-naphthol, nitrosobenzene, and isonitroso acetophenone. The noble metal halide is preferably a halide of palladium, rhodium, iridium, rhenium, platinum, and mixtures thereof. The catalyst system may also include molybdenum trioxide or another metal oxide.

This invention relates to an improved process for a preparation of organic isocyanates from organic nitro compounds in which a catalyst system comprising a halide of a noble metal and a nitroso compound is employed.

Organic isocyanates are used extensively in the preparation of urethane foams, coatings, and fibers as well as in the preparation of insecticides, pesticides and the like. Commercial process for preparing organic isocyanates utilize the catalytic hydrogenation of an organic nitro compound to form the corresponding amine, followed by reaction of the amine with phosgene to form the corresponding isocyanate. These processes are complex and expensive, and the need for a simplified, less expensive process is apparent.

In order to provide a simplified technique, it has been proposed to react an organic nitro compound with carbon monoxide in the presence of a catalyst. For example, British Pat. No. 1,025,436 discloses a process for preparing isocyanates from the corresponding nitro compounds by reacting an organic nitro compound with carbon monoxide in the presence of a noble metal-based catalyst. This process is not used commercially, because no more than trace amounts of organic isocyanates are formed when an organic nitro compound such as dinitrotoluene is reacted with carbon monoxide using a noble metal-based catalyst, such as rhodium trichloride, palladium dichloride, iridium trichloride, osmium trichloride, and the like.

Other proposed simplified techniques utilize other catalyst systems. For example, Belgian Pat. No. 672,405 entitled Process For The Preparation Of Organic Isocyanates, describes the use of a catalyst system of a noble metal and/or a Lewis acid in the reaction between an organic nitro compound with carbon monoxide.

Unfortunately, the yield of organic isocyanate afforded by these simplified techniques has not been significant enough to justify their use on a comercial scale.

It is a primary object of this invention to provide an improved process for the preparation of organic isocyanates.

Another object of the invention is to provide a novel catalyst system useful in the direct conversion of organic nitro compounds to the corresponding organic isocyanates.

Still a further object is to provide an improved process for preparing aromatic isocyanates such as phenyl 1S0- cyanate, toluene diisocyanates, and isocyanato-mtrotoluenes.

Patented Jan. 25, 1972 These and other objects of the invention will be apparent from the following detailed description thereof.

It has now been discovered that the above-mentioned objects are accomplished when an organic nitro compound is reacted with carbon monoxide at an elevated pressure and an elevated temperature in the presence of: (I) a catalyst system comprised of:

(A) at least one nitroso compound selected from the group consisting of (1) an aromatic compound of the formula R RI wherein R is selected from the group consisting of:

a. NO, and

O NO

R is selected from the group consisting of:

(c) hydrogen, and R" is selected from the group consisting of:

(e) hydrogen, (f) alkyl, (.2) y (h) alkaryl, (i) aralkyl, (j) alkoxyaryl, (k) aryloxy; and (2) a compound of the formula wherein R, R and R" have the same meaning as previously described; and

(B) at least one halide of a noble metal, or (II) a catalyst system comprised of a complex of a compound of LA and a halide of I-B.

In R" above, the alkyl group contains between 1 and 8 carbon atoms, including methyl, ethyl, isopropyl, n-butyl, isoamyl, n-hexyl, isohexyl, n-octyl, etc. The aryl and aryloxy moieties contain between 6 and 12 carbon atoms, such as phenyl, xylyl, naphthyl, tolyloxy, and the like. The alkaryl group contains 6 to 12 carbon atoms and includes tolyl, ethylphenyl, xylyl, etc., while the aralkyl group contains 6 to 12 carbon atoms and includes benzyl, phenylethyl, etc. Useful alkoxyaryl moieties have from 7 to 14 carbon atoms and include methoxyphenyl, ethoxyphenyl, propoxyphenyl, ethoxytolyl, etc.

Any organic nitro compounds capable of being converted to an organic isocyanate may be employed as a reactant. Generally, aromatic, cycloaliphatic, and aliphatic monoor poly-nitro compound, which may be substituted, if desired, can be reacted to form the corresponding monoor poly-isocyanates by the novel process of this invention. The term organic nitro compound, is used throughout the description and claims to define unsubstituted as well as substituted organic nitro compounds of the type described herein. Typical examples of suitable organic nitro compounds which can be reacted to form isocyanates include the following:

(I) Aromatic nitro compounds (a) Nitrobenzene (b) Nitronaphthalenes (c) Nitroanthracenes (d) Nitrobiphenyls (e) Bis(nitrophenyl)methanes (f) Bis(nitrophenyl)ethers (g) Bis nitrophenyl thioether (h) Bis(nitrophenyl)sulfnes (i) Nitrodiphenoxy alkanes (j) Nitrophenothiazines (II) Nitrocycloalkanes (a) Nitrocyclobutane (b) Nitrocyclopentane (c) Nitrocyclohexane (d) Dinitrocyclohexanes (e) Bis(nitrocyclohexyl)methanes (III) Nitroalkanes (a) Nitromethane (b) Nitroethane (c) Nitropropane (d) Nitrobutanes (e) Nitrohexanes (f) Nitrooctanes (g) Nitrooctadecanes (h) Dinitroethane (i) Dinitropropanes (j) Dinitrobutanes (k) Dinitrohexanes (l) Dinitrodecanes (m) Phenyl nitromethane (n) Bromophenylnitromethanes (o) Nitrophenyl nitromethanes (p) Methoxy phenyl nitromethanes (q) Bis- (nitromethyl) cyclohexanes (r) Bis-(nitromethyl)benzenes All of the aforementioned compounds may be substituted with one or more additional substituents such as nitro, nitroalkyl, alkyl, alkenyl, alkoxy, aryloxy, halogen, alkylthio, arylthio, carboxyalkyl, cyano, isocyanato, and the like, and employed as reactants in the novel process of this invention. Specific examples of suitable substituted organic nitro compounds which can be used are as follows:

2-chloro-6-nitrotoluene 4-chloro-3-nitrotoluene 1-chloro-2,4-dinitrobenzene 1,4-dichloro-2-nitrobenzene alpha-chloro-p-nitrotoluene 1,3 ,S-trichloro-2-nitrobenzene 1,3,5-trichloro-2,4-dinitrobenzene 1,2-dichloro-4-nitrobenzene alpha-chloro-m-nitrotoluene 1,2,4-trichloro-S-nitrobenzene 1-bromo-4-nitrobenzene l-bromo-Z-nitrobenzene 1-bromo-3-nitrobenzene 1-bromo-2,4-dinitrotoluene 0t,ot-dibIOl11O-P-Ilitl"0t0l[16116 a-bromo-p-nitrotoluene 1-fluoro-4-nitrobenzene l-fluoro-Z,4-dinitrobenzene l-fiuoro-Z-nitrobenzene o-Nitrophenyl isocyanate m-Nitrophenyl isocyanate p-Nitrophenyl isocyanate o-Nitroanisole p-Nitroanisole p-Nitrophenetole o-Nitrophenetole 2,4-dinitrophenetole 2,4-dinitroanisole 1-choloro-2,4-dimethoxy-S-nitrobenzene l,4-dimethoxy-Z-nitrobenzene m-Nitrobenzaldehyde p-Nitrobenzaldehyde p-Nitrobenzoylchloride m-Nitrobenzoylchloride 3,S-dinitrobenzoylchloride Ethyl-p-nitrobenzoate Methyl-o-nitrobenzoate m-Nitrobenzenesulfonylchloride p-Nitrobenzenesulfonylchloride o-Nitrobenzenesulfonylchloride 4-ch1oro-3-nitrobenzenesulfonylchloride 2,4-dinitrobenzenesulfonylchloride 3-nitrophthalic anhydride p-Nitrobenzonitrile m-Nitrobenzonitrile 1,4-dinitrocyclohexane Bis(p-njtrocyclohexyl)methane l-nitro-n-hexane 2,2-dimethyl-l-nitrobutane 1,6-dinitro-n-hexane 1,4-bis(nitromethyDeyclohexane 3,3'-dimethoxy-4,4-dinitro-biphenyl 3,3-dirnethyl-4,4-dinitro-biphenyl In addition, isomers and mixtures of the aforesaid organic nitro compounds and substituted organic nitro compounds may also be employed, as well as homologues and other related compounds. Compounds which have both nitro and isocyanato substituents, such as 2-is0- eyanato-4-nitrotoluene, may also be employed as a reactant.

The process of this invention is particularly effective in the conversion of aromatic nitro compounds to aromatic isocyanates. As used herein, the term aromatic nitro compounds represents those aromatic nitro compounds having at least one nitro group attached directly to an aromatic hydrocarbon nucleus, such as benzene, naphthalene, and the like, wherein the aromatic hydrocarbon nucleaus may be substituted as illustrated above. Among the preferred aromatic nitro compounds which may be used in the practice of this invention are the nitrobenzenes, both monoand polynitro, including the various nitrated toluenes and the nitrated xylenes; nitrated biphenyl and nitrated diphenylinethylene. Other preferred reactants include bis(nitrophenoxy)alkylencs and bis(nitrophenoxy) alkyl ethers. Generally, the organic nitro compounds and substituted organic nitro compounds contain between 1 and about 20 carbon atoms, and preferably between about 6 and about 14 carbon atoms.

The catalyst system of this invention is comprised of at least one nitroso compound and at least one noble metal halide. The nitroso compounds useful in this invention are selected from the group consisting of (1) a compound of the formula:

fin

wherein R is selected from the group consisting of:

a. NO. and

b. -OCH2 ll i R' is selected from the group consisting of:

(c) hydrogen, and R" is selected from the group consisting of:

(e) hydrogen, y (2;) y (h) alkaryl, (i) aralkyl, (j) alkoxyaryl, (k) aryloxy; and

(2) an aromatic compound of the formula:

RI! RI wherein R, R and R" have the same meaning as previously described.

In the process of this invention certain nitroso compounds have been found to be especially efficacious when used With the noble metal halides. Especially useful nitroso compounds falling within this classification include:

(a) nitrosobenzene (b) l-nitro'so-2-naphthol (c) 2-nitroso-1-naphthol (d) isonitrosoacetophenone Examples of nitroso compounds useful in the catalyst system of this invention include:

(24) 4-phenoxy nitrosobenzene (25 2-toloxy nitrosobenzene (26) l-nitroso-Z-naphthol (27) 2-nitroso-1-naphthol (28) 1-nitroso-4-methyI-Z-naphthol l-nitroso-3-iso'hexyl-2-naphthol 2-nitroso-5-isopropyl-l-naphthol 3-nitroso-4-n-hexyl-l-naphthol 1-nitros0-3-phenyl-2-naphthol 1-nitroso-4-phenylethyl-2-naphthol 2-nitroso-5-phenylisopropyl-l-naphthol 2-nitroso-5-butyltolyl-l-naphthol l-nitroso-2-ethyl naphthalene l-nitroso-4-n-butyl naphthalene 1-nitroso-3-is0heptyl naphthalene l-nitro'so-2-phenyl naphthalene l-nitroso-Z-methylphenyl naphthalene 1-nitroso-2-isohexylphenyl naphthalene 2-nitroso-3-ethylphenyl naphthalene 2-nitroso-4-phenylisobutyl naphthalene 3-nitroso-7-isoamyl naphthalene 3-nitroso-4-isohexylphenyl-2-n'aphthalene 1-nitros0-3-n-octylphenyl naphthalene 2-nitroso-l-phenylethyl naphthalene 2-nitroso naphthalene 4-nitroso naphthalene 2-nitroso-3-phenyl naphthalene isonitrosoacetophenone 4-methyl isonitrosoacetophenone 3-isobutyl isonitrosoacetophenone Z-n-octyl isonitrosoacetophenone Z-hydroxy isonitrosoacetophenone 2-hydroxy-3-methyl isonitrosoacetophenone 2-hydroxy-3-phenyl isonitrosoacetophenone 2-methoxyphenyl isonitrosoacetophenone Z-ethylphenyl isonitrosoacetophenone 4-isoamylphenyl isonitrosoacetophenone 2-hydroxy-4-phenylethyl isonitrosoacetophenone 3-phenoxy isonitrosoacetophenone The second component of the catalyst system is at least one halide of a noble metal. Noble metals include ruthenium, rhenium, rhodium, palladium, osmium, iridium, platinum, silver, and gold. The halides of palladium, rhodium, platinum, iridium, rhenium, and mixtures thereof are particularly preferred noble metal halides. Typical examples of suitable halides include palladous bromide, palladous chloride, palladous fluoride, palladous iodide, rhodium tribromide, rhodium trichloride, rhodium trifluoride, rhodium triiodide; ruthenium dichloride, ruthenium trichloride, ruthenium tetrachloride; osmium dichloride, osmium trichloride, osmium tetrachloride; platinic bromide, platinous bromide, platinic chloride, platinous chloride, platinic fluoride, platinous iodide, platinic iodide, rhenium trichloride, rhenium tetrachloride, iridium tribromide, rhenium hexafluoride, rhenium tribromide, iridium, tribromide, iridium tetrabromide, iridum triodide, iridium tetraiodide, and mixtures thereof. An especially useful group of noble metal halides includes palladous chloride, rhodium trichloride, iridium trichloride, platinic chloride and mixtures thereof. Oxides of the noble metals may also be employed and the term halide of a noble metal is used throughout the description and claims is intended to include the above-mentioned metal halides as well as the corresponding oxides, such as palladium oxide, rhodium oxide, platinum oxide, etc., and the like.

The use of the nitroso compound in catalytic combination with the noble metal halide is generally accomplished by adding the nitroso compound and the noble metal halide separately to the reaction system or, if desired, they may be premixed prior to adding the organic nitro compound. However, it has also been determined that complexes which can be formed by reacting the noble metal halide and the nitroso compound also can be utilized very effectively as the catalyst system in the conversion of the nitro compounds to isocyanates with carbon monoxide. These complexes are conveniently prepared by the reaction of the nitroso compound with the previously recited noble metal halides. For example, palladous chloride and isonitrosoacetophenone are heated together in refluxing orthodichlorobenzene until the former dissolves. The solution is then cooled and evaporated to dryness under reduced pressure, yielding crystals of a complex formed from the palladous chloride and the isonitrosoacetophenone. Thus, it is to be understood that in the practice of this invention the use of the nitroso compound in combination with the use of the noble metal halide may involve either the separate addition of each to the reaction system or, if desired, the prior formation of a complex of the two materials and subsequent use thereof in the reaction.

The catalyst system can be self-supported or deposited on a support or carrier for dispersing the catalyst system to increase its effective surface. Alumina, silica, carbon, barium sulfate, asbestos, bentonite, diatomaceous earth, fullers earth, and analogous materials are useful as carriers for this purpose.

The reaction is carried out in the presence of a catalytic proportion of the catalyst system. The proportion of catalyst system is generally equivalent to between about 0.001 and about 500 percent, and preferably between about 1 and about 100 percent by weight of the organic nitro compound. However, greater or lesser proportions may be employed if desired.

The molar ratio of the nitroso compound to the noble metal halide is generally between about 0.1 and about and preferably between about 0.5 and about 4.0 but greater or lesser ratios may be employed if desired.

The process of this invention operates effectively in the absence of a solvent, but improved overall yields of the organic isocyanates can be obtained when a solvent which is chemically inert to the components of the reaction system is employed. Suitable solvents include aliphatic, cycloaliphatic, or aromatic solvents, such as n-heptane, cyclohexane, benzene, toluene, and xylene, and halogenated aliphatic and aromatic hydrocarbons such as dichloromethane, tetrachloroethane, trichlorotrifluoroethane, monochloronaphthalene, and perchloroethylene, as well as sulfur dioxide, mixtures thereof and the like.

The proportion of solvent is not critical and any proportion may be employed which will not require excessively large equipment to contain. Generally the weight percent of organic nitro compound in the solvent is in the range between about 5.0 and about 75 percent, but greater or lesser proportions may be employed if desired.

The order of mixing the reactants is not critical and may be varied within the limitations of the equipment employed. In one embodiment, the organic nitro compound, catalyst system, and if desired, solvent, is charged to a suitable pressure vessel such as an autoclave which is preferably provided with agitation means such as a stirrer or an external rocking mechanism. At start-up after purging the system with nitrogen gas, carbon monoxide is fed into the autoclave until a pressure is attained, at ambient temperature, which is generally between about and about 10,000 p.s.i.g. After the reaction proceeds and heat is applied, the pressure may increase to as high as 30,000 p.s.i.g. The preferred reaction pressure is between about 100 and about 20,000 p.s.i.g. However, greater or lesser pressure may be employed if desired.

Generally, the quantity of carbon monoxide in the free space of the reactor is sufiicient to maintain the desired pressure as well as provide reactant for the process, as the reaction progresses. The reaction is believed to progress in accordance with the following equation:

where R is the organic moiety of the organic nitro compound reaclant of the type defined above, and n is the number of nitro groups in the organic nitro compound.

The total amount of carbon monoxide added during the reaction is generally between about 3 and about 50 and preferably between about 8 and about 15 moles of carbon monoxide per nitro group in the organic nitro compound. Greater or lesser amounts may be employed if desired. The highest carbon monoxide requirements are generally utilized in a process in which the carbon monoxide is added continuously, but suitable recycle of the carbon monoxide-containing gas streams greatly reduces the overall consumption of carbon monoxide.

The reaction temperature is generally maintained above about 25 C. and preferably between about C. and about 250 C. Interior and/or exterior heating and cooling means may be employed to maintain the temperature of the reactor within the desired range.

The reaction time is dependent upon the organic nitro compound being reacted, temperature, pressure and on the amount of catalyst being charged, as well as the type of equipment being employed. Usually between one-half hour and 20 hours are required to obtain the desired degree of reaction, in a batch technique, but shorter or longer reaction times may be employed. In a continuous process, the reaction may be much lower, i.e., substantially instantaneous, and residence time may be substantially less than batch reaction time.

The reaction can be carried out batchwise, semi-continously or continuously.

After the reaction is completed, the temperature of the crude reaction mixture may be dropped to ambient temperature, the pressure vessel is vented, and the reaction products are removed from the reaction vessel. Filtration or other suitable solid-liquid separation techniques may be employed to separate the catalyst from the reaction product, and fractional distillation is preferably employed to isolate the organic isocyanate from the reaction product. However, other suitable separation techniques such as extraction, sublimation, etc., may be employed to separate the organic isocyanate from the unreacted organic nitro compound and any by-products that may be formed.

Organic isocyanates produced in accordance with the technique of this invention are suitable for use in preparing polyurethane compositions such as foams, coatings, fibers and the like by reacting the organic isocyanate with a suitable polyether polyol in the presence of a catalyst and, if desired, a foaming agent. In addition, the organic isocyanates may be used in the preparation of biologically active compounds.

Some improvement in the conversion and yield of organic isocyanates can be obtained by employing a cata lyst system which not only contains a nitroso compound and a noble metal halide but also contains a third component comprised of certain metal oxides. Oxides suitable as a third component of the catalyst system include at least one oxide of an element selected from the group consisting of vanadium, molybdenum, tungsten, niobium, chromium, tantalum, and iron, as described in co-pending application Ser. No. 619,158, filed Feb. 28, 1967, for Process, by Schnabel et al. and Ser. No. 757,105, filed Sept. 3, 1968, for Noble Metal Catalyst System Containing Oxide of Iron by Rao et al. These elements, with the exception of iron, are found in Groups Va and VIa of the Periodic Table shown on p. 122 of Inorganic Chemistry by Moeller, John Wiley and Sons, "Inc. 1952. Suitable oxides of this type include chromic oxide (Cr O chromium dioxide (CrO chromous oxide (CrO); molybdenum sesquioxide (M0 0 molybdenum dioxide (M00 molybdenum trioxide (M00 niobium monoxide (NbO), niobium oxide (NbO and niobium pentoxide (Nb O tantalum dioxide (Ta O tantalum tetraoxide (Ta O and tantalum pentoxide (Ta O tungstic oxide (W0 and tungstic trioxide (W0 vanadium dioxide (V 0 vanadium trioxide (V 0 vanadium tetraoxide (V 0 vanadium pentoxide (V 0 ferrous oxide (-FeO) and ferric oxide (Fe O Mixtures of two or more of these oxides may be employed as one component of the catalyst mixture. The proportion of the third component of the catalyst system, when one is employed, is generally equivalent to a weight ratio of the noble metal halide to the metal oxide in the catalyst system generally in the range between about 0.00121 and about 25:1, and preferably in the range between about 0.005:1 and about :1.

The following examples are presented to describe the invention more fully without any intention of being limited thereby. All parts and percentages are by weight unless otherwise specified.

EXAMPLE I In this example, 2,4-dinitrotoluene(5.0 g.), palladous chloride (PdCl (0.4 g., 2.26 moles) and l-nitroso- 2-naphthol (2.26 10* moles) were charged to a clean, 100 ml. stainless steel autoclave (316 grade) together with orthodichlorobenzene solvent (5 ml.).

The autoclave was sealed after being so charged, then pressured with nitrogen and tested for leaks. Nitrogen was released and the autoclave was pressured with carbon monoxide to about 2500 p.s.i.g. During the reaction the autoclave was rocked in a rocker (36 cycles per minute), and heated during one hour to 190 C., when the internal pressure rose to about 800 p.s.i.g. This temperature was maintained for three hours, and then reduced to ambient temperature. After venting, the contents were discharged and weighed, and the autoclave was rinsed with two 5 ml. portions of orthodichlorobenzene. Insoluble matter present (unreacted catalyst or solids formed during the reaction) was filtered from the reaction mixture and washed with dichlorobenzene, and then ether. The wash solutions was subjected to a determination of its infrared spectrum to test for the presence of isocyanates (which possess a characteristic infrared light absorption at about 4.5 microns). The weight percentages of 2,4-dinitrotoluene, 2,4-toluene diisocyanate, 2-isocyanato-4-nitrotoluene and 4-isocyanato-Z-nitrotoluene in the filtrate were determined by vapor phase chromatography. The conversion of 2,4-dinitrotoluene was calculated to be 53 percent. The yield of 2,4-t0luene diisocyanate and the comibned yield of mononitrotolyl isocyanates were calculated and corrected for the amount of 2,4-dinitrotoluene which was recovered. The yield of toluene diisocyanate was 2 percent and the total yield of isocyanate products was 37 percent.

For purposes of comparison, additional experiments were carried out employing a procedure similar to that of Example I except that the catalyst was solely PdCl or solely RhCl Not more than a trace of isocyanate was detected in these experiments.

EXAMPLES II-XII The procedure of Example I was repeated except that the catalyst system employed was varied as shown in Table 1. Other pertinent details are also given in Table l which follows:

What is claimed is:

1. In the process for preparing an aromatic isocyanate by reacting an aromatic nitro compound containing up to about 20 carbon atoms with carbon monoxide at an elevated temperature and an elevated pressure in the presence of a catalyst, the improvement which comprises employing as said catalyst, a catalyst system selected from, the group consisting of (I) a mixture of (A) a nitroso compound selected from the group consisting of (1) a compound of the formula RI! RI wherein R is selected from the group consisting of:

Rn RI wherein R, R and R" have the same meaning as previously described; and (B) a noble metal compound selected from the group consisting of noble metal halides and noble metal oxides, and (II) a complex of a compound of I-A and a noble metal compound of 'IB, (III) wherein the molar ratio of said nitroso compound to said noble metal compound in said catalyst sys TABLE 1 Catalyst Moles of nitroso Percent yield Noble compound] metal Percent by male noble Percent Total Example halide weight 1 Nitroso compound metal halide conversion TDI 2 product PdClz 8 l-nitroso-Z-naphthol 2: 1 51 5 25 RhCl 8 do 1:1 61 13 55 Rhcla 8 2:1 73 6 24 RhCl 8 1: 1 50 3 41 PdClz 1:1 58 5 49 PdClz 8 2: 1 40 3 29 RhCl 8 3: 1 98 2 l2 RhCh 8 1:1 86 6 39 RhCl; 2: 1 9 2 15 RhCh 8 Nitrosobenzene 1:1 77 9 54 RhOl 8 Isonitrosoacetophenone. 1:1 80 47 2 2,4-toluene diisocyanate.

11 tem is in the range between about 0.1:1 and about 10:1, and (IV) wherein the noble metal of said noble metal compound is selected from the group consisting of palladium, rhodium, iridium, platinum, rhenium, ruthenium and mixtures thereof.

2. The process of claim 1 wherein the molar ratio of said nitroso compound to the anion of said noble metal compound is in the range between about 0.5 and about 4:1.

3. The process of claim 1 wherein the proportion of said catalyst system is between about 0.001 and about 500 weight percent of said aromatic nitro compound.

4. The process of claim 1 wherein the proportion of said catalyst system is between about 1 and about 100 weight percent of said aromatic nitro compound.

5. The process of claim 1 wherein said aromatic nitro compound is selected from the group consisting of nitrobenzene, dinitrotoluene and isocyanato-nitrotoluene.

6. The process of claim 5 wherein said catalyst system contains a third component comprised of an oxide of a metal selected from the group consisting of vanadium, molybdenum, tungsten, niobium, chromium and tantalum.

7. The process of claim 5 wherein said nitroso compound is selected from the group consisting of:

(a) nitrosobenzene (b) l-nitroso-Z-naphthol (c) 2-nitroso-1-naphthol -(d) isonitrosoacetophenone 8. The process of claim 7 wherein said noble metal compound is selected from the group consisting of palladous chloride, rhodium trichloride, iridium trichloride, rhenium trichloride, platinum tetrachloride and mixtures thereof.

9. The process of claim 8 wherein said catalyst system is a mixture of palladous chloride and 1-nitroso-2-naphthol.

10. The process of claim 8 wherein said catalyst system is a mixture of rhodium trichloride and 2-nitroso-1-naphthol.

11. The process of claim 8 wherein said catalyst system is a mixture of rhodium trichloride and 2-nitroso-1-naphthol.

12. The process of claim 8 wherein said catalyst system is a mixture of rhodium trichloride and nitrosobenzene.

13. The process of claim 8 wherein said catalyst system is a mixture of rhodium trichloride and isonitrosoacetophenone.

14. The process of claim 8 wherein said elevated pressure is in the range between about 30 and about 30,000 p.s.i.g., said elevated temperature is in the range between about 100 C. and about 250 C., and the proportion of carbon monoxide is in the range between about 3 and about moles of carbon monoxide per nitro group in said aromatic nitro compound.

15. The process of claim 8 wherein the proportion of said catalyst system is between about 1 and about weight percent of said aromatic nitro compound.

16. The process of claim 15 wherein the molar ratio of said nitroso compound to the anion of said noble metal compound is between 05:1 and 4: 1.

17. The process of claim 16 wherein said elevated pressure is in the range between about 100 and about 20,000 p.s.i.g., said elevated temperature is in the range between about 100 C. and 250 C., and the proportion of carbon monoxide is in the range between about 8 and about 15 moles of carbon monoxide per nitro group in said aromatic nitro compound.

18. The process of claim 16 wherein said catalyst system contains a third component comprised of an oxide of a metal selected from the group consisting of vanadium, molybdenum, tungsten, niobium, chromium and tantalum.

19. The process of claim 18 wherein said oxide of a metal is selected from the group consisting of chromic oxide (Cr O chromium dioxide (CrO and chromous oxide (CrO); molybdenum sequioxide (M0 0 molybdenum dioxide (M00 and molybdenum trioxide (M00 niobium monoxide (NbO), niobium oxide (NbO and niobium pentoxide (Nb O tantalum dioxide (Ta O tantalum tetraoxide (Ta O and tantalum pentoxide (Ta O tungstic oxide (W0 and tungstic trioxide (W0 vanadium dioxide (V 0 vanadium trioxide (V 0 vanadium tetraoxide (V 0 vanadium pentoxide (V 0 and mixtures thereof.

References Cited UNITED STATES PATENTS 3,461,149 8/1969 Hardy et al 260453 3,467,687 9/1969 Hardy et al. 260453 CHARLES B. PARKER, Primary Examiner D. H. TORRENCE, Assistant Examiner US. Cl. X.R.

252429 A, 429 C, 430; 260429 R, 430, 689 

